gabions brochure

Gabion Solutions

= Welded Mesh Gabions

= Land Reinforcement and Architectural Applications

www.hy-tengabions.com t: 01902 7122001

Based at Wolverhampton since 1987, Hy-Ten Gabion Solutions is the leading uk manufacturer of welded mesh gabions and mattresses for civil and architectural applications in both standard and bespoke unit sizes.

Hy-Ten's range of gabion systems and accessories are detailed in this brochure, in addition Hy-Ten offer an innovative design service for both civil and architectural projects.

Hy-Ten Gabion Solutions is a division of Hy-Ten Ltd which was established in 1958 and has a nationwide network of eleven manufacturing centres.

In addition to gabions, Hy-Ten manufactures and distributes a comprehensive range of fencing products, industrial mesh, concrete reinforcement, structural steelwork, galvanised lintels and sheet piling.

Hy-Ten is the exclusive UK manufacturer and supplier of Bamtec - concrete slab reinforcement in a roll.

For more details on our products and services, visit www.hy-tengabions.com or our group website at www.hy-ten.co.uk

Introduction to Hy-Ten Gabion Solutions

CONTENTS

2 Welded Mesh Product Specification

3 Wire and Wire Coatings

4 Welded Mesh Box Gabions

5 Welded Mesh Trapezoidal Gabions Gabion Fencing

6 Welded Mesh Gabion Mattresses Timber Faced Walling

7 Welded Mesh Gabion & Mattress Sizes

8 HY-TEN 700 System Gabions Technical Support Helical Connectors

f: 01902 714096 [email protected] 2

Welded Mesh Product Specification

WELDED MESH GABIONS, MATTRESSESAND ROCK NETTING PRODUCTS ARE AVAILABLE IN THE FOLLOWING SPECIFICATIONS...

TRIPLE LIFE COATINGS (95% ZINC 5% ALUMINIUM)

For non aggressive applications:Retaining structures in non aggressive environmentsFresh water applicationsCladding of structuresFree standing wallsGabion fencingRockfall protection

PVC-ZINC COATINGSFor structures in aggressive applications:Saline water environmentsRetaining structures subject to salt sprayLandfill structuresRockfall protection

STAINLESS STEELFor structures in aggressive applications or for architectural structures.

SHORT FORM OF SPECIFICATION

TRIPLE LIFE COATED GABIONS:Gabions shall be manufactured from hard drawn weldedwire, mesh size 76.2mm x 76.2mm (available in wire diameters 3.0mm, 4.0mm, 5.0mm).The wire shall be coated with Triple Life corrosion protection (95% Zinc 5% Aluminium) having a minimumcoat weight of 240 grams per square metre.

The gabion units shall be supplied with appropriate lacing wire or helicals for assembly and erection.

All wire to conform to BS1052.

PVC-ZINC COATED GABIONS:Gabions shall be manufactured from hard drawnwelded wire, mesh size 76.2mm x 76.2mm with zinc

and green PVC coatings (available in wire diameters of 3mm\3.50mm and 3.8\4.3mm), product

name 'MASTERPLAX'. 'MASTERPLAX' is produced to the following international standards...Wire to BS1052.Zinc coating to BSEN10244-2:2001.PVC coating system, fusion bond method according toDIN3036 part 2 and ASTM-F 688-88 type class 2b. Class 2b PVC-coated wire has the PVC coating fused and adhered to a primer that is cured on to the galvanized steel core wire. Minimum coating thickness is0.25mm.

The mesh complies with BS2782 Part 5, using method 540B(IS04892), as required by the 'White Book' 6.26/4 - August 1994.Hy-Ten Welded Mesh Gabions comply with the HighwaysAgency White Book specification, as detailed in section:6.26/4, and amended August 1994, and and the new European

WELDED BOX GABIONS WELDED GABION MATTRESSES

/British Standards BSEN10223-8:2013.

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Wire and Wire Coatings

TRIPLE LIFE COATINGS

Triple Life corrosion protection is a 95% Zinc, 5% Aluminiumcoating, applied to the wire prior to fabrication of thewelded mesh. Triple Life is a trade name for the process

developed by The Galfan Institute and is the same product as referred to by other trade names such as

Bezinal or Galmac. Each manufacturer provides itsown trade name for the process and is licensed

by The Galfan Institute.

Zinc-aluminium coatings are superior to traditional zinc coatings in that the rate ofcorrosion is parabolic as opposed to linear.The reason for the parabolic rate of corrosion

is that zinc corrodes at a faster rate than aluminium, hence, during the corrosion process

as the zinc element corrodes, an aluminium rich surface is developed which has greater resistance

to corrosion, thereby extendingthe life of the protection.

A further advantage of thecoating is that it has afiner microstructure andprovides better cathodic protection.Accordingly, should the surface become scratched the corrosion protection is maintained(it is sometimes referred toas self healing).

Based on long term site trials, it hasbeen established that the durability of the zinc-aluminiumcoatings is three to four times the life expectancy of a pure

zinc coating of the same coating weight.

For gabion manufacture, zinc-aluminium coatingshave replaced the traditional zinc coatings

and in some cases have replaced PVC-zinc coatings (except in extreme exposure conditions where gabions aresubjected to saline or salt spray).

WIRE

Where flexibility of the unit is required (e.g. erosion control structures) a 3mmwire is suitable.

For structural works 2m to3m high, a 3mm wirediameter is normally adequate. However,some deflection ofthe face may occurif the fill to the unitsis not hand packedon the face of thestructure. To improvethe quality of installation and alignment, the units canbe specified with a heavier facing mesh in 4mm or 5mmwire.

For structural works 3m to 6m high, a3mm wire diameter with a heavier facing mesh of 4mm or 5mm wire is normally adequate.

For structures over 6m, it is recommended to use 5mm wire for thelower courses, changing to 4mm for theupper courses.

For specialist applications such asarchitectural facings where ahigh quality of construction is required, the minimum wire diameter should be 4mm.



Welded Mesh Box Gabions

Cladding to Structures

National Aquatic Centre, Dublin

Constructed 2003

River Structures

Betchworth, Surrey

Constructed 2003

Mass Gravity Retaining Walls

Holmfirth (Gabion 700 system)

Constructed 2003

Architectural Walling

Scottish Agricultural Science Agency

Constructed 2006


Welded Mesh Trapezoidal Gabions

Trapezoidal Gabion Walling

Gateshead International Stadium

Constructed 2006

Free Standing Walls

Regatta Centre, Royal Albert Docks,London

Constructed 1999

Boundary Walling Structures

Housing Development, Sports City,Manchester

Constructed 2003

Housing Development, Sports City,Manchester

Constructed 2003

Gabion Fencing


Welded Mesh Gabion and Mattress Sizes

Standard Welded Mesh Gabion Sizes

Corrosion Protection Triple Life Coated PVC-Zinc CoatedMesh Size 76.2mm x 76.2mm 76.2mm x 76.2mmUnit Size Wire Diameters Wire Diameters

1m x 1m x 1m 3.0, 4.0, 5.0mm 3.0, 3.8mm

1.5m x 1m x 1m 3.0, 4.0, 5.0mm 3.0, 3.8mm

2m x 1m x 1m 3.0, 4.0, 5.0mm 3.0, 3.8mm

3m x 1m x1m 3.0, 4.0, 5.0mm 3.0, 3.8mm

1m x 1m x 0.5m 3.0, 4.0, 5.0mm 3.0, 3.8mm

1.5m x 1m x 0.5m 3.0, 4.0, 5.0mm 3.0, 3.8mm

2m x 1m x 0.5m 3.0, 4.0, 5.0mm 3.0, 3.8mm

3m x 1m x0.5m 3.0, 4.0, 5.0mm 3.0, 3.8mm

Standard Welded Mesh Mattress Sizes

Corrosion Protection Triple Life Coated PVC-Zinc CoatedMesh Size 76.2mm x 76.2mm 76.2mm x 76.2mmUnit Size Wire Diameters Wire Diameters

3m x 2m x 0.15m 3.0, 4.0, 5.0mm 3.0mm

3m x 2m x 0.225m 3.0, 4.0, 5.0mm 3.0mm

3m x 2m x 0.3m 3.0, 4.0, 5.0mm 3.0mm

3m x 1m x 0.15 3.0, 4.0, 5.0mm 3.0mm, 3.8mm

3m x 1m x 0.225 3.0, 4.0, 5.0mm 3.0mm, 3.8mm

3m x 1m x 0.30 3.0, 4.0, 5.0mm 3.0mm, 3.8mm

700 System Gabion Sizes

Corrosion Protection Triple Life Coated PVC-Zinc CoatedMesh Size 76.2mm x 76.2mm 76.2mm x 76.2mmUnit Size Wire Diameters* Wire Diameters

2m x 0.7m x 0.7m 3.0mm with 4.0mm face and rear panels 3.0mm with 3.8mm face and rear panels







2m x 3m x 0.7m 3.0mm with 4.0mm face and rear panels 3.0mm with 3.8mm face and rear panels

* Heavier Mesh Specification Available

Non-Standard sizes manufactured to customers specification


HY-TEN 700 Gabion System

HY-TEN Technical Support

Technical support from feasibility through design to completion.

Design Service using dedicated software.

Specialist projects undertaken using bespoke design and manufacture.

Comprehensive technical publications available on our web site www.hy-tengabions.com

The HY-TEN 700 Gabion System is essentiallya standard gabion unit. The sizing, manufacture and mesh/wire have beenchosen to optimise the design and improvethe ease and quality of construction.

The system is based on a unit with a nominalheight of 700mm and of standard length2m, subdivided into cells of 700mm. Themanufacture is based on a traditional unitwhere the sides and diaphragms are connected to the base so that it folds flatfor ease of transportation.

The units are supplied with an extendedbase where necessary so that the base ofone unit will form the lid of the unit below.All lids, bases, transverse diaphragms andside panels are manufactured from 76.2mmx 76.2mm x 3.0mm welded mesh panels. The face, rear and longitudinal diaphragmsare manufactured from 76.2mm x 76.2mm x4.0mm to enhance quality and ease ofinstallation.

Jointing for manufacture is with clips orrings. Site assembly is with helicals on vertical joints and helicals, rings or lacingwire on the horizontal joints.

THE BENEFITS OF THE SYSTEM:

Better distribution of mesh reinforcement in the structure.

The unsupported mesh face is 700mm x 700mm which reducespossible deformation of the face to 25% of that of a standard 1mx 1m unsupported face of the same wire diameter. Greaterreduction is achieved with a mesh face of 4.0mm wire diameterswhich leads to a higher quality of construction.

A superior quality facing can be achieved as it is easier for theoperative to hand pack the front face.

Helicalling the vertical joints is simple and gives consistent jointstrength over its full length and provides the most efficient jointsystem. The cut end wires of the panel are enclosed within thehelical thereby ensuring that snagging can be minimised(health and safety issues).

A greater range of wall heights and course widths can beachieved to give the optimum economical design solution.

By utilising a maximum unsupported mesh face of 700mm square,wall inclinations can be increased to 10 degrees without givingrise to construction problems, resulting in more cost effectivedesign.

The system is cost competitive compared to traditional 1m deep units and reduces construction costs.

Helical connectors for assembly and erection of gabions. Provide a consistent quality of joint. The cut end wires of the panel are enclosed within the helicalthereby ensuring that snagging can be minimised (health and safety issues). Supplied as an additional item to standard gabions.Supplied as standard with the HY-TEN 700 Gabion System(Vertical Joints).

Helical Connectors


Welded Mesh Accessories

MC50 Pneumatic ‘C’ Ring Pliers

Enables 40 operations per minute, maximum capacity.

Accepts standard 50mm ‘C’ rings in stainless steel or triple life coated.Stainless steel rings in boxes of 1,000.Triple life rings in boxes of 1,600.

Rock Anchor Square Plate Washer

To customer’s specification.Galvanised to ISO1461 if required.

Rock Anchor Threaded Rebar

To customer’s specification.Supplied with Hexagonal Nuts to suit.

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Main Sales Office12 The Green, Richmond, Surrey TW9 1PXTel: 020 8940 7578 Fax: 020 8332 1757Email: [email protected]

Middlesex Works, Gresham Road, Staines, Middlesex TW18 2BJTel: 01784 463551 Fax: 01784 466758Email: [email protected]

Kent Works, Chatham Docks, Chatham, Kent ME4 4SWTel: 01634 280504 Fax: 01634 280491Email: [email protected]

Dorset Works, 2 Holton Road, Holton Heath Trading ParkPoole, Dorset BH16 6LTTel: 01202 624733 Fax: 01202 624796Email: [email protected]

West Midlands Works1, Unit 1, Dunstall Hill Trading EstateWolverhampton, West Midlands WV6 0PJTel: 01902 712200 Fax: 01902 714096Email: [email protected]

North West Works, Bridle Road, Bootle, Merseyside L30 4UGTel: 0151 525 1745 Fax: 0151 523 2252Email: [email protected]

East Midlands Works, Newark Storage Ind. Estate, Bowbridge Road,Newark, Nottinghamshire NG24 4EQTel: 01636 700418 Fax: 01636 605179Email: [email protected]

www.hy-ten.co.uk

Hy-Ten Group’s Sales Offices and Manufacturing Centres:

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Oxfordshire Works, Unit 7A Bushell Business EstateWallingford Oxfordshire OX10 9DDEmail: [email protected]

Scotland Works Central Rebar Ltd, Unit 11, RiverbankKelliebank Industrial Estate Alloa FK10 1NU

West Midlands Works2, Unit 54 Wellington Industrial EstateCoseley West Midlands WV14 9EETel: 0800 037 1018 Fax: 01902 673323Email: [email protected]

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Tel: 0800 037 1710 Fax: 01259 215129

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Devon Works, KB Reinforcement Ltd, Round head Road

Email: [email protected]: 01626 240 644

Fax:01626 832825

Heathfield Industrial Estate, Newton Abbot Devon TQ12 6GY

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